Vehicle suspension member and method for making

ABSTRACT

A vehicle suspension member such as leaf spring (50) is provided having at least one plate (3) having an irradiation exposed region (R) therein that is generally parallel to a longitudinal axis (&#34;L/A&#34;) extending between opposite ends of plate (3) and operative to provide a metallurgical discontinuity extending therealong between opposite ends thereof that is effective to divert crack propagation in a direction generally parallel to axis (&#34;L/A&#34;).

This application is a division of Ser. No. 666,967 filed Mar. 11, 1991,pending.

INTRODUCTION

This invention relates generally to a vehicle suspension member andmethod for making same exemplary of which a leaf spring comprising asingular or plurality of plates or leafs having a metallurgicallyaltered region therein that is substantially parallel to a longitudinalaxis extending therealong between opposite ends of the plate of leaf andoperative to provide at least one discontinuity therein effective todirect or divert crack propagation in a direction generally parallel tothe longitudinal axis.

BACKGROUND OF THE INVENTION

Although coil springs have recently come into favor for passenger carsuspension systems, leaf springs remain in favor for use particularly intruck, suspension systems, and are likely to for many years to comebecause of the load capacity, packaging and axle location advantagesassociated therewith. Although described herein with particularity toleaf springs, the present invention includes any vehicle suspensionmembers subject to torsional or bending loads and having a longitudinalaxis extending between opposite ends such as torque rods (also calledtrailing arms, for axle control); traction bars (keep axle from twistingduring braking); and track rods (keep axle from shifting laterally).

Leaf springs generally comprise a singular leaf or plate or a pluralityof leafs or plates that may be made from constant or tapered thicknessplates or leaves. most commonly made from steel and secured together andoperative to support the frame of the vehicle on the wheel axle. Asmight be expected, the number of leafs or plates employed in the leafspring is based on allowable design stress for a given load capacity anddeflection range.

Each plate of a leaf spring is subjected to bending producing a(positive) tensile stress on the upper, typically concave, surface ofthe leaf to which the vehicle load or force is applied. As a result, abalancing (negative) compressive stress is developed on the lower,typically convex, surface of the leaf. The tensile stress is a maximumat the upper surface of the leaf and decreases to zero at or near thecenter of the plate thickness also known as the neutral axis hereinafterreferred to as longitudinal axis extending between opposite ends of theleaf or plate. Similarly, the balancing compressive stress is a maximumat the lower surface declining to zero at the longitudinal axis.Virtually all cracks are initiated at or near the upper surface of theleaf spring plate at the point of maximum tensile stress.

Due to high strength requirements, leaf springs must have high hardnessthat is associated with rapid crack propagation through the leafcross-section once a relatively shallow crack is developed at thetensile surface. The incidence of crack initiation and progression isgenerally a function of increased service life or time and also serviceconditions including load history and corrosion. No matter how a crackmay develop, i.e., fatigue and/or corrosion, its progression beyond acritical depth of generally less than on-half of section thickness israpid to complete fracture or separation.

The present invention provides a means of detering or diverting crackpropagation which initiates at or near the upper tensile surface andprogresses through the thickness of the leaf or plate in a directionessentially perpendicular to the longitudinal axis of the leaf byredirecting crack progression to a direction generally parallel thereto.Effectively, the parallel crack or delamination of the flat (or tapered)plate section lowers section stiffness causing the spring to sag wellbefore final fracture providing the user some early indication ofimpending spring failure prior to complete separation and possiblevehicle debilitation.

SUMMARY OF THE INVENTION

Accordingly, it is an object of this invention to provide a vehicularsuspension member having a longitudinal axis extending therealongbetween opposite ends thereof and having a metallurgical discontinuitytherein effective to divert crack propagation in a direction generallyparallel thereto.

It is another object of this invention to provide a method for making avehicle suspension member having a longitudinal axis extendingtherealong between opposite side thereof and having a metallurgicaldiscontinuity therein effective to divert crack propagation in adirection generally parallel thereto.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a vehicle suspension leaf spring 50 showingcrack propagation;

FIG.2 is a cross section taken along view line 2--2 through leaf spring50 of FIG. 1;

FIG. 3 is a schematic block diagram of a preferred embodiment of amethod of making leaf spring 50 of FIGS. 1 and 2;

FIG. 4 is a cross section of a leaf spring 100 made in accordance withthe invention;

FIG. 5 is a schematic block diagram of a variation on the embodiment ofthe method shown in FIG. 3; and

FIG. 6 is a cross-section of a leaf spring 100 made in accordance withthe method of FIG. 5.

DESCRIPTION OF SOME PREFERRED EMBODIMENTS

Leaf spring 50 of FIG. 1 is illustrative of the manner in which crackpropagation is deterred in accordance with the invention. Spring 50characteristically comprises at least one flat or tapered leaf or plate3 having a substantially rectangular cross section as shown in FIG. 2that extends between opposite ends (not shown) that are adapted such asby being formed into eyelets to secure spring leaf 50 to a vehicle frameor perhaps to another suspension system that is secured to the vehicleframe. In some instances it may be preferable to omit eyelets. Commonlyonly one plate in a stacked plurality of spring leaf plates need haveeyelets at one or both of its opposite ends. Although shown in FIG. 1 astapering towards it opposite ends to provide the greatest thickness atits center, plate 3 may also have a substantially constant thicknessthroughout its entire length as is well known to those skilled in leafspring art.

Plate 3 has a longitudinal axis "L/A" referenced by numeral 4 thatextends therealong between opposite ends thereof. Since the crosssection of leaf or plate 3 is generally symmetrical, axis "L/A" willgenerally pass through the center thereof as shown in FIG. 1.

Generally, when plate 3 is repetitively bent, such as by repetitivebending loads "P₁ " and "P₂ " at the point of securement (not shown inFIG. 1), a reaction force "F" is created at the spring seat thatcommonly bridges across the center thereof and which has ultimatelycaused a crack to occur at the upper tensile surface due to fatigue asdenoted by reference numeral 8. But rather than cracking completelythrough plate 3 the crack propagation has been directed or diverted in adirection generally parallel to axis "L/A" a distance "L" because of ametallurgical discontinuity that has been purposely introduced withinplate 3 as hereinafter described.

As used herein, the word "discontinuity" means a discontinuity inmechanical properties situated along a single plane or along multipleplanes that are disposed in a direction generally parallel to thelongitudinal axis but not necessarily continuous therealong. Ininstances where the suspension member is a leaf or plate subject tobending loads, the discontinuity is preferably disposed near the neutralaxis of the leaf or plate.

The metallurgical discontinuity arises from an irradiation exposedregion "R" purposefully introduced therein that is generally parallel toaxis "L/A".

One method by which metallurgically altered region "R" referenced bynumeral 10 in FIG. 2 is created is by exposure to radiation hereinafterdescribed with respect to FIG. 3.

In FIG. 3, a plate 50 is provided having a substantially rectangularcross section having a longitudinal axis "L/A" extending through thecenter since the cross section is generally symmetrical.

At least one side and preferably both sides of plate 50 are exposed toradiation 12 emitted from a radiation source 14 that directs radiation12 preferably towards the center of the edge of plate 50 so as to createregion "R" symmetrically about axis "L/A" and in generally parallelrelationship thereto.

It is known that radiation of sufficient energy can impinge upon andimpart energy to the metal molecules sufficient to heat the metal to anannealing temperature at which grain growth is initiated and even to atemperature sufficient to cause the metal to melt (here remelt) and thensolidify upon cooling. As such, radiant energy is able tometallurgically alter the metal in region "R" since the width or breadthof the radiation beam and the focal point can be controlled with highdegree of accuracy by means of masks, magnetic fields, optical and otherdevices well known to those skilled in the art.

Preferably, the radiation is high energy electron radiation such asdescribed in U.S. Pat. No. 4,644,126, the disclosure of which isincluded herein by reference. As set forth therein, and for purposes ofthis invention the term "radiation" includes electron or laser beam typeradiation as well as proton or helium ion beams from a duo-plasmatronall of which will melt and subsequently weld metal when focused to ahigh enough power density.

As an example, an electron beam having a radiance of from about 10⁸ to10¹¹ watt/cm² steradian or a laser beam having a radiance of about 10⁶to 10⁸ watt/cm² -steradian is quite capable of melting metal.

The radiation particle energy is able to be focused at a precise targetsuch as the location of axis "L/A" extending along a vehicle suspensionspring leaf.

The radiation beam energy imparted to plate 50 of FIG. 3 providesmetallurgically altered region "R" by focused annealing and even meltingwhich creates a difference in the grain structure operative to createthe metallurgical discontinuity that is effective to divert crackpropagation in a direction generally parallel to axis "L/A" as shown inFIG. 1.

FIG. 4 illustrates the principle that radiation heating is mosteffective when focused as a cone shaped radiant beam upon an objectwhich, in the case of FIG. 4, is towards opposite edges of spring leaf100, with radiation beam 18 having an included angle alpha As such, 60.The thickness "T₁ " at the center of region"R" of plate 16 is less thanthe thickness "T₂ " of region "R" of plate 16 shown in FIG. 4. In suchinstances the taper of the cone can be controlled such that region "R"at the side or edge still remains in general parallel relationship toaxis "L/A" across the breadth of spring leaf 100.

Also illustrated in FIG. 4 is the principal that the differential inthickness between "T₂ " and "T₁ " can be minimized by exposing oppositesides or edges of plate 16 to radiation such that the focal point ofeach beam extends past the center of plate 16 such that the radiationbeams 18 overlap at the center of plate 16 as shown in FIG. 4.

Preferably, the average thickness of region "R" for a spring leaf havinga thickness of about 0.250 inch is from about 0.050 to about 0.080 inchor generally from about 1/4 to about 1/3 the total thickness of thespring leaf plate.

FIG. 5 shows a variation of the method of FIG. 3 where only one edge ofthe spring leaf plate is exposed to radiation only from one side toprovide a tapered region "R" referenced by numeral 10 having an includedangle. This is most advantageous for thick and narrow width platesections thus offering attractive economics. In such cases the anglealpha (8) of the beam created the acceptable "T₃ " and "T₄ " affectedregion thickness for the needed fatigue life as shown in FIG. 6.

It is desired to control the thickness of the affected region "R" assmall as possible so as to generate an abrupt metallurgically alteredregion to enchance crack retardation and deflection. Hence, for thicksections, as in the order of 0.500 inch or greater, it is desirous tomaintain the "T₃ " and "T₄ " to about 0.050 to about 0.080 inch.However, greater thicknesses are permitted as stated above from about1/4 to about 1/3 the total thickness of the spring leaf plate.

The methods of FIGS. 3 and 5 apply to both constant thickness plates andto plates or leaves having a tapered thickness along their lengths aswould commonly be used for single leaf suspension once appropriatetooling and/or computer control is implemented to guide the energy beamalong the longitudinal axis.

What is claimed is:
 1. A vehicle suspension member comprising at leastone metal member having a longitudinal axis extending therealong betweenopposite ends thereof, said member having an irradiation exposed regiontherein that is disposed in general parallel relationship to thelongitudinal axis and operative to provide a metallurgical discontinuitytherein effective to divert crack propagation in a direction generallyparallel thereto.
 2. The suspension member of claim 1 wherein theirradiation exposed region is a high energy electron beam irradiationexposed region.
 3. The suspension member of claim 1 wherein themetallurgical discontinuity is a solidified remelt discontinuity.
 4. Thesuspension member of claim 3 wherein the solidified remelt discontinuityis a solidified irradiation remelt discontinuity.
 5. The suspensionmember of claim 4 wherein the solidified irradiation remeltdiscontinuity is a solidified high energy electron beam irradiationremelt discontinuity.
 6. The suspension member of claim 1 in the form ofa leaf spring having at least one plate having the longitudinal axisextending therealong between opposite ends thereof and having themetallurgical discontinuity disposed therein in general parallelrelationship thereto.
 7. A method of making a vehicle suspension memberhaving a longitudinal axis extending therealong between opposite endsthereof, said member having a metallurgically altered region thereinthat is generally parallel to the longitudinal axis and operative toprovide a discontinuity therein effective to divert crack propagation ina direction generally parallel thereto, and said method comprisingexposing at least one edge of the member to radiation in a mannereffective to provide the metallurgically altered region that isgenerally parallel to the longitudinal axis.
 8. The method of claim 7wherein the radiation is high energy electron beam radiation.
 9. Themethod of claim 7 wherein the metallurgically altered region is asolidified metallurgically altered remelt region.
 10. The method ofclaim 9 wherein the solidified metallurgically altered remelt region isa solidified metallurgically altered irradiated remelt region.
 11. Themethod of claim 10 wherein the solidified metallurgically altered remeltregion is a solidified metallurgically altered high energy electron beamirradiated remelt region.
 12. The suspension member of claim 1 whereinthe irradiation exposed region is a high energy laser beam irradiationexposed region.
 13. The method of claim 7 wherein the radiation is highenergy laser beam radiation.
 14. The leaf spring of claim 6 wherein theplate tapers towards its opposite ends.